World Applied Sciences Journal 25 (3): 536-542, 2013

ISSN 1818-4952
© IDOSI Publications, 2013
DOI: 10.5829/idosi.wasj.2013.25.03.7061

Modeling of the Separation Process in Dynamic Separators

Rashid Rizaevich Sharapov, Vladislav Stanislavovich Prokopenko and

Rinat Rashidovich Sharapov

Belgorod State Technological University Named After V.G. Shukhov,

Russia, 308012, Belgorod, Kostyukov Street, 46

Submitted: Aug 18, 2013; Accepted: Sep 26, 2013; Published: Oct 3, 2013
Abstract: The advantages of use closed circuit grinding cement clinker and additives into a ball mill shown.
A mathematical model of the process separation of fine powders in view of the separation of air flow turbulence,
allowing to investigate the separation process based on the fractional composition of the finished product
presented.

Key words: Separator The separation efficiency The boundary size Turbulent diffusion

INTRODUCTION A common characteristic is the quality of separation

Cement production is a high tech industry that
consumes significant energy resources. Thus one of the
ways to improve the efficiency of cement production is
the use of closed circuit grinding, as raw materials and
cement clinker [1, 2]. The implementation of closed circuit
grinding is carried out in a variety of designs grinders
with air separators, which also went a long way in its
development [1, 3, 4]. However, the dynamic separators,
separators so-called third generation, which recently
equipped with grinding units, do not always provide the
high performance separating, which generally reduces the
efficiency of the entire production of cement [1, 3, 4].
Improving the efficiency of air separators can be achieved
by improving and changing their modes of operation.
One of the key parameters describing the operation of the
separator, the quality of separation is a original material,
which can be estimated by the ratio of control of certain
sizes, such as:
d25 (1)
= ,
d75
where d25 and d75 – mesh sizes, for which the complete
remains of the finished product are 25 and 75 % of its
initial weight.
With increasing separation accuracy index value [chi]
is approaching unity. The ratio of [chi] can be found in
sufficient detail disperse composition of the finished
product.
performance indicator represents the difference between
the relative yield of fine and coarse fractions (D3) original
material (Q1, D1) in the finished product (Q2, D2):
Q2 D2 Q2 R2 ( D2 − D1 )( D1 − D3 )
Es = − = 104 (2)
Q1D1 Q1R1 D1 (100 − D1 )( D2 − D3 )
Currently, with the modernization of cement plants
cement mills are equipped mainly with dynamic separator
with outer zone deposition in which a separation fan and
deposition of the finished product system brought
outside of the separator.
Separators third generation produced by leading
manufacturers (Sturtevant-D company Sturtevant, USA;
Sepmaster SKS company KHD Humboldt Wedag AG,
Germany; Sepol company Krupp Polysius AG, Germany;
O-Sepa company Onoda, Japan; Sepax company FL
Smidth, Denmark and etc.). They differ from each other by
means of separation load, air supply systems and
outputting the original material and product separation
rotor drive separator, ratios main dimensions and
constructional features, etc. Thus a common feature of all
these is a combination of impingement and centrifugal
separation of the particles.
Consistent theory and based on her strict
methodology of calculation of dynamic separators does
not yet exist. Therefore, to calculate the approximate
separators used methods based on simplified
mathematical models aero material traffic flows as well as

Corresponding Author: Rashid Rizaevich Sharapov, Belgorod State Technological University Named After V.G. Shukhov,
Russia, 308012, Belgorod, Kostyukov Street, 46
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 World Appl. Sci. J., 25 (3): 536-542, 2013

empirical correlations, which generalize the experimental model of the gas-dispersed flow does not take into
data, as well as experience in operating such devices account the turbulence of the gas-dynamic flow and
[5, 6]. distribution of fractions within the finished product,
The most important indicator of the operating which is very important in predicting the construction and
separator is the boundary size d1, in which there is a technological properties of the obtained powders.
division of the finished product and grains. The theory of turbulent gas-dispersed flows still
The most accurate definition of the boundary size being developed, so it is now widely used approximate
and study its dependence on the design parameters of the mathematical models based on simplified assumptions and
device is possible only on the basis of differential the results of experimental studies. One such assumption
equations of motion of particles in a vortex of air [7]. is the hypothesis is negligibly small, the relaxation time of
In a cylindrical coordinate system, these equations the particle velocity (approaching the main field).
are: According to this hypothesis, particle in the field of mass
dVr V
2
C Re forces with acceleration a (M), instantly acquires a
=− D (Vr − U r ); velocity:
dt r 24
dV VrV CD Re 24 p
=
− − (V − U ); V (M ) = a( M ), (4)
dt r 24 CD Re
where M – the point of the force field, = d2 2 /(18µk )
dVz C Re (3) – dynamic relaxation time of the particles. For Stokes flow
− D (Vz − U z ) + g ;
=
dt 24 regime (Re < 1), formula (4) takes the form:

dr d V dz V(M)= a(M).
= V=r, =, Vz ,
dt dt r dt
In this zone the particle centrifugal force Fc directed
where Vr, V , Vz, Ur, U , Uz – radial, circumferential and radially towards the periphery:
axial components of the velocity of the particle and the air
2
carrier medium, respectively: r, and z – the current value = d3 d3 V , (5)
Fc 2 = ac 2 ⋅
of the radius of the polar angle and the axial position of a 6 6 r
particle; CD – drag coefficient; Re = d 3 |V – U|/µ – and flow pressure force directed toward the center:
Reynolds parameter characterizing the flow regimes of the
particle; ð = d2 2/(18µk ) – relaxation time, indicating the d2 (Vr − U r )2 (6)
Fn = CD k .
duration of the particle acceleration to the speed of the air 4 2
environment. In [8], the boundary separation is determined from the
The system of equations (3) is supplemented by the F = Fï, however, these conditions are satisfied for all
initial conditions determining the coordinates and velocity particle sizes on the equilibrium of circular trajectories
components at the initial time, the relations describing the corresponding radiuses. Therefore, given in [8] ratio:
surface, restricting of the aero material flow, including the
moving surface of the rotor cage, as well as input and 3 V2 (7)
= d1 CD k 3 ⋅ r
output surfaces of the particles, the ratios determining the 4 2 ac
velocity field of the carrier air flow, i.e. dependence of the can not be practically used because of the uncertainty
velocity of air from the origin. and Vr ac.
The system of equations (3) can only be solved Seems more reasonable definition of the boundary
numerically, for example, using the Runge-Kutta method. size on the basis of the expression for the radial velocity
Changing to a certain particle size, the initial position on of the particles [9]. In the quasi-stationary approximation
the input surface, can be found the relative proportion of (dVr / dt = 0) for the Stokes flow regime (CD = 24/Re) from
these particles submitted to the finished product. Solving equation (3) we get:
this problem for the whole range of particle size can be
considered to calculate the curve division separator. V2 (8)
V=r Ur + .
Note that this calculation is associated with large r
computational difficulties and the results are not Circumferential speed of the particle near rotor blades
completely reliable, since the underlying mathematical (r = RL) is equal to:

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 World Appl. Sci. J., 25 (3): 536-542, 2013

UL = 2 RL nr, (9) According to (15) the duration of the transverse

motion of the particle is:
as it get closer to the axis of the separator decreases and  1 
approaches to zero. RL2  . (16)
t ( R0,5 → RL )
= 2( k −1)
− 1
The distribution of the radial velocity of air is 2U12 p ( k − 1)  x0,5 

determined from the condition that its flow rate Lc:
The velocity of particles in an upward flow of air is a
Lc (10) difference rate of air flow and gravitational settling
Ur = − ,
2 hr velocity of the particles:
where h – height of the separation zone and the sign "–"
4 Lc
indicates the direction of Ur to the axis of the separator. Vz
= − g p, (17)
In view of the formulas (9) and (10) the relation (8) Dc 2
becomes:
where Dc – interior diameter of the separator in the zone of
U L2 p 2k −1 Lc (11) separation. Substituting formula (16) and (17) in the
=Vr r −
RL2k 2 hr condition (12) after transformation obtain:
Since d1 corresponds to the fraction of the original
product, which is evenly divided between the finished
72 Lc
product and the grains, then it is logical to assume that d1 = .
the boundary of separation corresponds to the 2  2 2 0,707 2( k −1)  g
Dc h 2  8 nr ( k − 1) +
 1 − (0,707) 2( k −1)  h
equilibrium path that divides the living cross section of 
the separator in r1 = k L / 2 . Taking into account the value (18)
of the radius of the condition Vr = 0, we obtain the relation
for calculating the size of the boundary: This formula but structurally – defined process
parameters, also contains one adjustment parameter k,
9 Lc 2k (12) which is determined by the results of processing of the
d1 = 3 2 2
.
4 RL h 2 nr experimental data.
Significant influence on the distribution of material in
In contrast to the formula (7), relation (12) comprises the separator has a turbulent flow of air separation,
only known parameters separator design values and one leading to a blurring of the trajectory of the particles and
adjustment parameter k, determined according to their spontaneous flow into the area of lower
industrial test separators. concentration of the dispersed phase due to turbulent
To determine the length of the transverse motion of diffusion of particles.
the particles in the separator consider the equation: Distribution of the concentration of particles in the
separation zone described by a stationary convection-
2
dr U (13) diffusion equation:
= p,
dt r
where the circumferential velocity of the air is given by 1 ∂  ∂C   ∂  ∂C  (19)
 r  CVr − Dr   +  CVz − Dz =0,
(10). r ∂r   ∂r   ∂z  ∂z 

Reduce (13) to a dimensionless form: where Vr, Vz – components of the velocity of the
dispersed phase, considered as quasi-continuous
dx U1 p 2k −1 (14) environment; Dr, Dz – radial and axial components of the
= x ,
dT RL tensor of turbulent diffusion coefficients of the gas
where x = r/RL, T = tU1/RL. suspension.
The study of two-phase swirling flows in a rigorous
From equation (14) we obtain: formulation is a complex task that can only be solved by
1   numerical methods. Therefore, to obtain approximate
RL RL  1
=T =
U1 p ∫x1− 2k dx
2U1 p (k − 1)  x 2(k −1)
− 1 ,

(15) analytical relationships we reduce equation (19) to the
two quasi-one-dimensional problems for the average
x0,5  0,5 
where x0,5 = R0,5/RL = 1/ 2 = 0,707 particle concentrations. Since considerable speed the aero

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 World Appl. Sci. J., 25 (3): 536-542, 2013

material flow in the separator (Uz = 8…12 m/s), the where x(d) – the coefficient particle inhomogeneity in flow
diffusion transfer of particles in the axial direction will be cross section, the size of which is defined by an orderly
neglected: Dz = 0. The first stage of modeling, i.e. by transfer of particles by centrifugal forces and oppositely
averaging the particle concentration in the radial variable directed diffusion flow.
r will not be considered as the diffusion particles in the In view of (25), equation (24) after simple
transverse direction. Then equation (19) can be rewritten transformations given in the following form:
as:
dC ( z ) 2V ( R ) (d )
∂ ∂ = − r r C ( z ).
∂r
( r ( CVr ) ) = − ( r ( CVz ) ) .
∂z
(20) dz RrVz (26)

Integrating equation (26) we get:

We integrate (20) for r in the range of 0 to Rr, where
Rr – the radius of the surface of separation of the flow of =  2V ( R ) (d )  (27)
C ( z ) C (0)exp  − r r z .
the gas mixture of the raw material to the finished product  RrVz 
and the rough (grains). As a result of integration, we get:
At z = h, where h – height of the separation zone,

2 dC ( z )
2 Rr C ( Rr , z ) Vr ( Rr ) = − Rr Vz , (21) from (27) that:
dz
C ( z )  2V ( R ) ( d ) h  (28)
(
= d ) = exp  − r r .
where C (z)-the particle concentration, averaged over the C  R V
r z 
cross section of the gas-dispersion stream:
Here = C 0 C= (0) Q / L – the concentration of
m c
Rr material in the flow axis; (d) – the distribution function
2 ∫ zC ( r , z ) dz of the separator is equal to the relative proportion of the

C ( z) = 0 . (22) starting material fraction (d; d + d), removal to the
Rr2 finished product. However, the relation (28) can not be
used for practical purposes, since it has an unknown
Multiplying both sides of (21) to dz obtain mass parameter x (d).
balance equation fraction of starting material (d; d + Ad) To study the heterogeneity of particle density
in a layer of separated material with thickness dz: distribution in the cross-sectional flow we integrate
equation (19) in the axial variable z in the range 0 to h,
2 
2 Rr dzC ( Rr , z )Vr (Rr , d ) = − Rr Vz dC ( z ), (23) assuming Dz = 0 and Dr = D = const (homogeneous
turbulence approximation).
ie reduction in the flow of particles of size d equal to the
flux of these particles through the surface of separation in d  dC  V
 rC ( r )Vr − D =− ( rC ( h, r ) − rC ( 0, r ) ) z ,
the course product. dr  dr  h (29)

Equation (21) can be rewritten as: where C (r ) – the concentration of particles, averaged
over the height of the separation zone.
dC ( z ) 2V (R , d ) h
= − r r C ( Rr , z ). 1
(24) (30)
dz RrVz C (r ) =
h ∫
C ( r , z )dz.
0
To solve equation (24) is necessary to express the
concentration of particles on the surface separation Integrating both sides of the equation with respect
C(Rr, z) by the concentration, averaged over the cross to r from 0 to r, we get:
section in this case we have the following expression:
 dC ( r ) 
2 kh  C ( r )Vr − D
dr 
= ( )
r 2Vz C ( 0 ) − C ( h ) ,
C ( Rr , z ) = (d ) C ( z ), (25)  (31)

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 World Appl. Sci. J., 25 (3): 536-542, 2013

where C (0), C ( h) – the particle concentration averaged  bPe 2 k1 

exp  x 
over the cross section r2. x0  2k1  − for horizontal centrifugal zone
Equation (31) expresses the mass balance of a narrow z = ⋅
x  bPe 2 k1 
fraction of particles in a cylindrical volume of radius r and exp  x0  (38)
 2k1 
height h: the difference between the flow of particles
passing through the inlet (z = 0) and the output section of Here x0 – empirical coefficient that determines the
the separator is equal to the total flux of particles passing limit of applicability of the formulas describing the flat
through the lateral surface of the volume in the separator vortex with a central drain.
including its diffusion component. To close the equation From the dependences of z = z (x) we can calculate
(31) we set Vz = 0, ie, consider the limiting case of the the coefficient of transverse inhomogeneity of the
concentration distribution of the particles, which would concentration distribution of the particles:
be formed in a confined space under the action of C ( Rr ) xr2z ( x p )
centrifugal forces and turbulent diffusion of particles. = = ,
C xr
Then equation (31) can be written as follows:
∫
2 xz ( x )dx
0
dC (32) (39)
D − Vr C =
0.
dr where xr = Rr /RL.
Reduce (32) to a dimensionless form: After transformations, the expression (39) is in mind:

1 dz (33)
− w( x) z =
0.  nr Pe p 2 k1 
Pe dx exp  xr 
 k1 .
C r RLU L =
Here=z = ; x ; Pe
= – the Peclet number; nr Pe p 2k
C0 RL D 1+ xr 1 (40)
k1 ( k1 + 1)
w = Vr/UL; RL – inner radius of the rotor rotating;
UL = 2 nRL – peripheral speed of the rotor blades. For conditions of separation, discussed earlier, we:
Dimensionless circumferential velocity of the particles to dz
separate different types of zones expressed by the p nr Pe t p = 0,0043 ,
Dc
formulas:
Vr ( Rr ) = 0,01d 2 xr2k −1.

bx 2 k1 −1 − for counter centrifugal zone. Then the expression for the separation function (28)
 (34) can be written as:
w=
2 k −1 a
bx 1 − − for horizontal centrifugal zone.
 x
  0,0043 xr2k 2  
Here k1 – the power law index, which characterizes  0,0027 xr2( k −1) d 2 exp  d 
  Dk 
(d ) exp  −
=   .
the distribution of the peripheral speed of the rotating air 2k 
 0,0043 x r d2 
flow separation (k1 = 2...4); b = 2 n p; p = d2 2/18µ – 1+
 Dk ( k + 1) 
dynamic relaxation particles time; a = Lc/2 RL h UL; Lc –   (41)
volumetric flow rate of air separation. Equation (33) in
view of (34) takes the form: Formula (41) contains three unknown parameters k,
xr and D, which can not be directly measured or found by
dz
= Pe bx 2 k1 −1z – for counter centrifugal zone (35) calculation. Their size can be estimated using the general
dx physical and mechanical considerations verified by
dz  a
= Pe  bx 2 k1 −1 −  z – for horizontal centrifugal zone experimental data. The magnitude of the turbulent
dx  x (36) diffusion coefficient of the particle can be estimated from
standard values of the Peclet number, Pe = 4...16 [10];
Solving equations (35) and (36) has the form: D 0,5...2 m2/s. By processing the available experimental
data, the following parameter values: xr = 0,7; D = 0,8 m2/s;
 bPe 2 k1 
z = exp  x  – for counter centrifugal zone (37) k = 3. In this case, the separation function takes the form:
 2k1 

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 World Appl. Sci. J., 25 (3): 536-542, 2013

(d) impact on both the efficiency of the distribution of the

1 peripheral speed of the carrier flow (parameter k) and the
radius of the surface separation xr.
2
Reducing the parameter can be achieved by reducing
the drag of the separator and increase in the initial
1
concentration of particles of the material flow of fines,
which causes additional energy dissipation of turbulent
pulsations that exerts influence on lamination aero
0,5 material flow in the separation zone.

Findings

A synthesis approach, which allows to consider the

basic structural and technological parameters of air
separators proposed.
A mathematical model of the process of separation of
0 20 d1 40 60 80 100 d,
micron the material, taking into account the separation of air
flow turbulence, taking into account both the
Fig. 1: Curves division, built on relationships: 1 – curve diffusion of particles as well as structural and
obtained by formula (42); 2 – a curve obtained by technological parameters of the separators, based on
formula (43) which an analytical expression for the separation
developed.

=
(
 0,00065d 2 exp 0,00021d 2
( d ) exp  −
) . It is shown that the main direction of increasing the
accuracy of classification of centrifugal separation of
 1 + 0,000053d 2 
  (42) cement, is to reduce turbulence in gas-dispersed
flow, which can be achieved by improving the
Separation curve, corresponding to the separation aerodynamic properties of the air path and the
function (42), shown in Fig. 1. increase in the concentration of fine particles in the
As can be seen in Fig. 1 considered the boundary load flow coming to the separation.
separating the separator corresponds to d1 30 microns.
REFERENCES
Fig. 1 also shows a plot Molerus [10]:
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(d ) = ,
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1 + exp   1 −  
d1 (43) 2. Reinchardt, Y., 2008. Effective Finish Grinding. World
 2  d1  
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